PT DEWHIRST

QUALITY MANAGEMENT SYSTEM (QMS)

 Section 1 :
Raw Material Activity
FABRIC INSPECTION AND FABRIC APPROVAL PROCEDURE
I. PURPOSE
To ensure the quality of fabric approval procedure

II. SCOPE
Inspection scope is checking for any defects, hand feel, colour, width, bowing/skewing,
design and face side of the fabric

III. WHEN AND WHERE

This procedures carried out when the factory receive the fabric from the supplier and
conduct by Fabric QA and Fabric Technologist.

IV. PROCEDURE
1. Fabric must be inspected 30% of total fabric roll received at the first time.
2. Fabric inspection on appreciate inspection frame / machine & using 4 point system.
1 Point : Faults with length less than 7.62 cm (warp or weft)
2 Point : Faults with length between 7.62-15.24 cm (warp or weft)
3 Point : Faults with length between 15.24-22.86 cm (warp or weft)
4 Point : Faults with length between 22.86-91.44 cm (warp or weft)
All holes must be counted as 4 points

Standard limit
DEWHIRST standard limit for the 4 point system are
 20 points/100 yard2 per roll
 Average 16 points/batch

3. Repeated fabrics : 10% checked if fails 40% checked, if still fails 100% inspection
carried out.
4. Fabric relaxed 24 hours after steaming process (with sponging machine for any fabric
containing more than 2% shrinkage) in Fabric Warehouse. The result record with
document list.
5. Inspection findings are properly recorded and reviewed on a timely basis by
supervisor. The result being inputted and kept to the data base (CITEX).
6. Light box used for color continuity
Colour should be assessed first with TL84 (store light) and then with D65 (daylight),
then checked in Tungsten filament for metamerism. A light box should be segregated
in order to prevent daylight leaking into the box.
7. Colour blanket made for each batch (side to side, start middle and end of roll)
8. Approved fabric hanger available at inspection area (colour, handle and appearance
checked)

Fabric Inspection Fabric Rejection Area

Colour Grouping Fabric Storage (Approved Area)

SPONGING PROCESS AND RELAX FABRIC PROCEDURE
I. PURPOSE
To make sure that fabric has no shrinkage after cutting

II. SCOPE
The procedure scope is at the Fabric Warehouse

III. WHEN AND WHERE

The process carried out prior to cutting and conducted at the Fabric Warehouse

IV. PROCEDURE
IV.1 Using Steam
a. Put the fabric on sponging machine which has fix speed which is 3 meters per
minute
b. Put the fabric after sponging to the flat wood to be relax within 24 hours to ensure
that fabric laid flat and no bubling
c. Measure the width from beginning, middle and end for position pin to pin &
sponging standard to make sure shrinkage on fabric
d. Make a note on sticker which contain, roll number, result sponging, pin to pin,
date & time of sponging process and attach it on the fabric.
e. Put the flat wood which already contain the fabric after sponging into stillage

IV.2 Without Steam

a. Put the fabric on sponging machine which speed with condition fabric
b. Put the fabric after relax to the flat wood to be relax within 24 hours to ensure
that fabric laid flat and no bubling
c. Measure for one position the width from beginning
d. Make a note on sticker which contain, roll number, result sponging, pin to pin,
date & time of sponging process and attach it on the fabric.
e. Put the flat wood which already contain the fabric after relax into stillage

Sponging Process Relaxing Process After Steaming

TRIMS QC INSPECTION PROCEDURE
I. PURPOSE
The objective of doing the QC check on the Trims is to ensure that the trims/accessories
received are within the standard

II. SCOPE
The procedure shall apply to all trims/accessories received in PT Dewhirst

III. WHEN AND WHERE

Trims/accessories inspection is carried out randomly when the goods received and before
enter the approved area. Checking carried out in trims QC inspection area at trims
warehouse

IV. PROCEDURE
1. Trims/accessories will be audited using AQL Normal Level II , 1.5% , BS6001 : 1999.
2. Batch size & sample size are determined according to the AQL standard against the
delivery quantity of each item.
3. All the trims/accessories delivery from the supplier must be kept in the quarantine
area within the trims warehouse prior to QC inspection.
4. All trims checked against Bulk Trims Card and CMS.
5. Ensure the trims/accessories is free from metal contaminant and already had checked
by the trims QC using the hand held metal detector (especially for zipper, elastic
hanger and other goods which contain the metal)
6. If the QC inspection failed then QC trims must chop the surat jalan/invoice with
“rejected” chop and fill in the relocate form then give them to the trims admin. The
goods must immediately segregated and moved to rejected area within the
warehouse by trims operator, then QC trims put “REJECTED” chop on the JDE sticker in
each package.
7. The QC inspection pass then QC trims must chop the surat jalan/invoice with “QC
APPROVED” chop and give the surat jalan/invoice to the trims warehouse admin.
Trims admin have to make and print JDE sticker (stating “QC PASSED”) then to be
attached by trims receiving operator on every goods packing declared as
pass/approved. The good must immediately moved from quarantine area to the
secure and locked area by warehouse operator.
8. Label quantities issued by the trim store must match the exact quantities of cut parts
delivered to the sewing section.
9. Labels are issued to the sewing lines by exact bundle quantity. Label quantities issued
should be by single size, or colour, and match the daily output targets for each line.l

Trims Receiving Area Trims Inspection Area

Quanrantine Area Trims Warehouse Layout

Brand Protection Area Light Box

 Section 2 :
Pre Production Activities
STYLE FILE REQUIREMENTS
I. PURPOSE
The style file is the main reference used for doing the garment inspection and must be
available

II. SCOPE
The procedure shall apply to pilot until final inspection

III. WHEN AND WHERE

The style file must be made for every new style. For flow style, it can refer to the previous
style file and must be updated for any changed item.

IV. PROCEDURE
1. Style file set up for each style
2. The style file should have following information/document
- Garment standard/Fit log
- Contract seal evaluation
- Risk assessment
- Pre Production Notes
- Bulk Component Card
- Fabric Hanger
- Size Chart
- Pilot Information (If available, ie.pilot evaluation & pilot meeting minutes)
- First Bulk audit reports
- Correspondence from Gartech UK if any special prints to note
3. Risk assessment must be analyzed and evaluated to identified as high \ medium or
low risk – so that everyone is aware from the beginning of the risks involves, and can
anticipate and negate those risks.
4. The sample garment risk assessment form will be completed at Development or Fit
Samples \ and Contract Seal sample stages – please see attached format.
5. The style file must be organized and completed by gartceh coordinator for each dept.
Prior to distribution to auditors on production floor. The Gartech Coordinator must
work together with Garment Technologist, Sample Manager, Merch. Purchaser to get
the complete requirements. The contract seal summary must be signed by Fabtech,
Sample Room Manager, Factory Manager and Technical Executive (30 minutes before
send the contract seal, Gartech coordinator or Ass. Gartech Coordinator will confirm
the Factory Manager for checking the contract seal and sign the summary, if within in
 30 minutes FM did not come it will be assumed that the FM has confirmed the
contract seal).
6. The style file must be distributed and available for reference at least 3 day before bulk
cutting started.
7. Style File must be used during the garment inspection at :
- First bulk audits
- Shipment release audit
- Management audit
8. Any changes to the construction after the contract seal process must be in writing and
agreed by the UK and put in the file.
9. All substitute trims/component must be duly signed and approved by either Technical
Executive or Site Quality Manager. The copy of approval card must be put into the
style file and the original must be filed into the substitute trims file.
10. All substitute trims/component must be duly signed and approved by either Technical
Executive or Site Quality Manager. The copy of approval card must be put into the
style file and the original must be filed into the substitute trims file.
11. Any changes and/or new information related to the style must be in writing and
agreed by the UK and put in the file.
Attachment-1. Garment Fit Log
Attachment-2. Risk Assesment
Attachment-3. Bulk Component Card
Attachment-4. Bulk Component Card Specimen
Attachment-5. Fabric Hanger
CONTRACT SEAL PROCEDURE
I. PURPOSE
This procedure serves as guide when making any contract seal garment while ensuring
that the M&S Standard and Dewhirst operational procedures are followed.

II. SCOPE
This sample making and logistical procedure shall be followed/reference by any or all of
the following: (1) Gartech coordinator (2) Pattern maker (3) Pattern manager and (4)
Sample manager

III. WHEN AND WHERE

Based on the sample schedule from the Gartech Coordinator, Contract Seal Samples will
have to be produced in the Sample Room. Rack Samples and Production Pilot samples will
on the other hand be produced or made in the Production Floor based.

IV. PROCEDURE
The following pointers will have to be adhered to when making the contract seal :
1. PP Notes,
Gartech Coordinator distributes the PP Notes to the Pattern Marker, Pattern Manager,
and Sample Manager.
2. The Pattern Manager will receive and review T1 pattern/block reference or revised
pattern (T2,T3 etc), size chart either from the UK or the Gartech Coordinator.
3. Review
The Pattern Maker, Pattern Manager and Sample Manager must review the sketch,
pattern, size chart and take note of any comments (if any).
4. Marker
The Marker made by the Pattern Maker will be approved by the Pattern Manager
based on :
 The review result ( as per point 3 )
 The shrinkage results from Fabtech for the fabric that will be used
 The face up fabric and cut direction
 Seam allowance
 Seam slippage
5. Fabric Sample
Gartech Coordinator will give the fabric sample, including the shrinkage results to the
Sample Room.
 (The fabric sample has to follows the required standard)
6. Fuse the Fabric
Key factors when fusing the fabric :
 The interlining reference that will be used
 The temperature, pressure and timing that will be used
 Bond strength result
7. Trims whether original or substitute will have to be confirmed by the Gartech
Coordinator.
8. Sewing
Ensure that the garment will be as per standard and that the sewing operator will
following the pattern / nest pattern
9. Documentation
The sample room must fill-up complete the following documents:
 Contract Seal sample summary
 Fit Log
 Sample Garment Risk Assessment

Form Sample Garment Risk Assessment will be completed at Development or Fit

Samples \ and Contract Seal sample stages – please see attached format. It will be
completed by the sample supervisor, noted by the sample room manager, aggred by
the fab tech manager ( if there are any comments regarding fabric ) , and approved by
the garment technical executive ( and for LWR blouses by the LWR Gar Tech
Manager ) .

A copy of the completed form will also be sent to the UK with the fit log and the
garment and any high or medium risk assessments wil be translated to English and
emailed by the Gar Tech Coordinators within 2 days to :

1. The UK Gartech and Fabtech

2. The PTD Fabric technologist and manager and dept head, MM, The Production
Director and Factory Manager, and the Merch Manager
 Dewhirst Technical Park Assessment
 Fabric Approval Card (approved by Fabtech)
 Bond Strength result (issued by Fusing Spv and approved by Sample
Manager and Technical Executive)
 The garment photo on all sizes (front+back) and photo on all
measurements stated on size charts (all sizes)
 Prior to sending the samples to the UK, the Sample Room Manager, the Gartech
Coordinator and the pattern maker/pattern maker managaer must review all
samples. Sending will only commence with the approval of the Technical
Executive.

The Contract seal available in factory and used for pilot/pre-production meeting.

Attachment-1. Contract Seal Summary

GARMENT PILOT PROCEDURE
I. PURPOSE
To give the production and quality team have a chance to “get to know and understand” a
style before it starts in bulk. Any special handling/machinery/machine attachments/work
methods, etc, should be identified during the pilot stage, so that the bulk style can be
correctly anticipated.

II. SCOPE
This procedure outlines all the necessary steps involved in the Pilot Sample Requirements.

III. WHEN AND WHERE

Pilot Schedule – When all decision are made about which styles to pilot, the Gartech
Coordinator for each factory will work with Merch team to fit the pilot into the
preproduction schedule. The preproduction is updated once a week by Merch and
distributed to Fabtech, Gartech and Production. So, that everyone is aware of the styles
that have to be made and when.

IV. PROCEDURE
1. Pilot Schedule
The Dewhirst Gar Tech will work with the factory to make pilot garments, and it is
expected that a pilot will be made for any new styles ( or repeat styles in a new factory
) – at least one piece for every size.
The factory must make a schedule that fits in with the production date requirements –
so that shipment dates are not affected.

2. Pilot Process
- Pilot fabric arrives on site, or is taken from bulk
Fabric testing – factory will do shrinkage tests on the fabric. Then this info is given
to the Dewhirst fab tech, who will approve the shrinkage info, and the face and cut
direction to the Pattern maker and the Dewhirst Gart Tech.
- Marker – the sample room will ask the pattern room to make the marker for the pilot
seal. This can only be done, when the fabric information above is given.
- Cutting – cutting room to the pilot
- Fusing – Fusing conditions based on specific recommendations for fusing conditions by
supplier
- Trims – use from bulk trims (BCC should be made before pilot)
- Sewing – the line that will make the bulk production will make the piot samples.
Dewhirst Gar Tech will give technical advice about construction and quality. Agreed standards
for all operations to be agreed during the pilot process. The standard will be made by the
operator who is directly doing the process, with the assistance of the trainer/supervisor. The
agreed standard must be signed by the QC manager , Production Manager and Dewhirst Gar
Tech and the operator.
- Washing process – done based on contract seal approval
- Test washes – care label and durability washes to be done – organized by Factory
- Evaluation – by the factory and approved by the Dewhirst Gar Tech
- Any changes required to patterns etc – must be proposed and agreed by Dewhirst Gar
Tech.

3. Pilot Documentation
The factory and Dewhirst Gar Tech must complete the following forms :
- Pilot Sample Summary Form
- Fit log
- Dewhirst Technical Pack Assessment
- Fabric approval card – which must be approved by the Dewhirst Fab Tech
- Bond Strength Result – approved by the sample room
- Manufacturing notes – any special m/c settings required for the style / any special
needles required/special pressing conditions etc.
- PreProduction Minutes
Note – if the pilot fails, the process must be repeated until the pilot passes. For a
style that requires a pilot – there must be a pass result before cutting of the bulk
style commences.

4. Pre Production Meeting

- Requirement – there must be a Pre Production Meeting for every style – whether or not
there is a pilot. This must take place before bulk cutting.
- Attendees – factory Quality Manager and Supervisor / Production Manager / Line
Supervisor / Engineer / Work Study or IE / Cutting Supervisor / Finishing Supervisor /
Merchandiser, and Dewhirst QC Auditor / Dewhirst Gar Tech / Dewhirst Fab Tech
- Minutes of meeting – there must be minutes taken from the meeting, which are acted
on by the necessary personnel, and filed in the style files.

5. Wearer Trials
If there are any new fabrics, trims, or new garment design feature/pattern – then a
wearer trial must be done from the first bulk – please see separate procedure for
details.
Attachment-1. Pilot Summary
Attachment-2. Elastic Report
 Section - 3 :
Production Activities

CUTTING AREA CONTROL

I. PURPOSE
To ensure that all cutting room activities have clearly defined parameters and control
document to give guidance to operator out the task
II. SCOPE
To cover all aspects within the cutting room, pre production manufacturing and delivery
circle.

III. WHEN AND WHERE

At all Dewhirst employee particularly those related to Cutting Room

IV. PROCEDURE
1. Markers are checked for style number, PO number, width, component. Grain line,
pattern/nap direction, notches & size etc prior to cutting.
2. QC checked spreading fabric for face side, center line, width/length fabric against
marker, layer, fabric defect & shade colour.
3. Cut parts cutting accuracy are checked against from top, middle & buttom plys and
compare with hard pattern for nothes, grain line & cut accuracy.
4. All sleeve length measured in the lay against specification and QC stamped.
5. Panels are 100% checked & report are kept for reference.
6. All checks/stripes have a full repeat booking allowance and are repined, and cut with
hand knifes/bandknifes.
7. All plains cut on the automatic gerber cutter nett.
8. Stretch fabrics are laid using the Auto Feeder which can have positive or negative
feed.
9. Separate customer tables to check individual panels Top Middle and Buttom
10. QC inspect whether components are bundled exactly as per information in the bundle
ticket, bundle neither to tight not too loose & numbering accuracy approval standard,
buyer requirement & matching available.
11. QC checked 100% fused panel as per standard approved and bond strength for ply
top, middle & bottom.
 Marker Checking

Spreading Process (Automatic Gerber) Interlining Process

Bandknife process Cutting Tables

100% Cut Panel Checking

Numbered Panel Checking Bundled Panel Checking

 Panel Bundled

Attachment – 1 : Cutting Quality Report

FUSING PROCEDURE
I. PURPOSE
To ensure that the conditions required allowing the generation of consistently fused
garment parts are met and maintained to the appropriate standards. To ensure that on
the spot quick and effective physical testing can be carried out at the workstation, giving
 clear, indisputable results which will then be used to trigger acceptance or rejection of
garment parts being processed with records of remedial actions taken as appropriate.
These tests must be used in addition to, not to replace other tests carried out in
laboratories, i.e. testing for delamination through durability washing etc.

II. SCOPE
This procedure covers the control of standards, the setting up and maintenance of all
cutting room and in-line process fusing presses used to bond interlinings to garment
fabrics.

III. WHEN AND WHERE

This test or tests will be carried out in cutting rooms. The attaching of badges, motifs or
other heat and pressure bonded embellishments should be tested in the same way as
other bonded pieces covered in this procedure where applicable. QC Testing and IPC
Fusing to carry out the testing of machine running temperatures, fusing peel bond
strength, shrinkage tests and other associated tasks as specified by fabric, technical or
quality departments.

IV. PROCEDURE
1. Fusing machines should be calibrated twice a day
2. Following are the point that has to be done in the fusing the garment :
a. Check The Temperature
Set the fusing machine to the conditions recommended in the fusing interlining
suppliers report. Allow 20-30 minutes for the machines to heat up and stabilize,
then place 3 temperature strips across the width of the machine, (Left, Center and
Right). Read the temperature from the strips once they have gone through the
machine

To read the temperature strip, locate the number in front of the darkest black
square. In this picture, the temperature is 116⁰C

b. Check The Fusing / Dwell Time

 Set the timer as recommended in the fusing report. Check the fusing/dwell time by
using an accurate stop watch to time a non adhesive fabric swatch going through
the machine. Start timing when the fabric enters the heating cabinet/zone.

c. Check The Pressure Evenness

Do the test on the 3 positions across the machine, left, centre and right at the
same time.

3. The trial for fusing condition (prior to production) ‘

The trial tests for glue line temperature and bond strength. To conduct the trials you
will need; temperature measuring strips, a spring balance, fabric from bulk which
needs to be slightly bigger than the interlining (17.2 cm x 7.2 cm) and the interlining
(17 cm x 7 cm).

4. Below is a flow process to show the trial process which should be actioned prior to
production :
a. Set the Fusing machine to the conditions recommended in the fusing report.
Allow 20-30 minutes for the machine to heat up. Ensure Machine calibration is
completed and correct.
b. Start the fusing trial. (With the prepared fabric, interlining and temperature strip).
The interlining must be cut 2mm smaller than the fabric being fused. Interlining
must never over-hang fabric edges.

c. After the fabric and interlining have been fused, check the appearance and the
glue line temperature.
d. Check the bond strength with the spring balance. If acceptable, bulk fusing can
begin.
 e. Test the peel bond strength and record standard minimum 800gr/2.5 cm and
1600gr/5 cm. Any result less than minimum standard, the machine has to be
adjusted. But if in such case where after the machine had been adjusted and the
result still not as per standard the result must be discuss with Cutting Room
Manager and Gartech Coordinator.
f. Wash test carried out and record the durability wash and measure for shrinkage.
g. Fuse fabric to establish initial fabric shrinkage and record it.

5. The maximum shrinkage for fabric after fuse is 2%. Any result exceeded 2% must be
discuss with Fabtech, Gartech Coordinator, fuse test person for immediate
verification.
6. The frequency of testing will be done for every machine at every 2 hours, in every shift
or four times per day, this should coincide with machine start up and after extended
periods of inactivity.
7. The factory should have a data sheet report for every fabric. All checked against
Interlining Supplier Data Sheet
8. The fusing operator for each shift must clean the machine in the beginning, and at the
end of their work time (also during work time if the machine is dirty).
9. For pilots, all tes results must be included into the pilot evaluation form, and has to be
given to the Garments Technologist on each respective T-numbers

Fusing process Fuse Panel Checking

Bond Strength Test

DEWHIRST QUALITY MANAGEMENT

Daily Fusing Record
INLINE PROCESS CONTROL (IPC) PROCEDURE
I. PURPOSE
The system is designed to give clear signal to trigger problem solving activities to all
participants, as well as generating record, which can indicate potential process
improvement. The system will focus those participating on problem solving in an
 appropriate timely, consistent and effective manner, resolving problems and thereby
continually improving the process.

II. SCOPE
The system is designed for use in bulk manufacturing and small team working areas, up to
and including final package and presentation.

III. WHEN AND WHERE

This procedures carried out when production process will and doing at line production
area.

IV. PROCEDURE
1. Sewing operation instructions and the quality standards should be available at each
sewing machine, with details of the machine set up which includes details as follows :
 Process and line
 Needle and Stitch Size
 Stitch Per Inch (SPI)
 Thread size and quality
 A detailed description of the operation, either by a detailed drawing or by
attaching a sample
2. Production Specification should be available together with Contract Seal.
3. Ensure the templates, guides used for accuracy for stitching.
4. To ensure the IPC mobility and process coverage, all single visit sample will consist of
10 garments (or depend on the bundle quantities). The total sample taken over the
day will eventually arrived at by the combination of the selection of priority or normal
status generating a required number of IPC plus those triggered when faults are
found.
5. Priority status will be decided upon and selected by observing historically poor trends
or assessing the operation on complexity and consistency of standards achievement.
Priority operations audited at at minimum of two per shift using the standard sample
of 10 garments per visit as a minimum.
6. Normal status operations are those which demonstrate that a consistent and
appropriate level of conformity to the required process standards can consistently
achieved with the minimal audit activity. Minimal audit activity can be described as
audit visits carried out at a minimum frequency of twice per shift.
7. The action triggers built into the system are designed to be flexible, easy to
understand and communicate, using traffic light signals to denote the process status,
i.e.
 a. No defects mark card GREEN. Go to next operator
b. ONE defect mark card YELLOW, circle defect number as applicable. #1, 2, 3, 4, 5, 6,
7, or 8. Inform and show operator the fault. Move to next operator.
c. TWO defect mark card RED, circle defect number as applicable. #1, 2, 3, 4, 5, 6, 7,
or 8.
 Inform and show line supervisor the faults
 Line Supervisor must stay with operator until 20 consecutive
garments/parts/operation/passes.
 Line Supervisor must initial or sign at the RED to indicate 20 garments have
passed consecutively.
d. THREE or MORE defects found mark card circle defect number as applicable. #1, 2,
3, 4, 5, 6, 7, or 8.
 Inform and show Sewing Line Supervisor/Manager.
 Manager & Supervisor must stay with the operator until 40 consecutive
garments have passed.
 Managaer & Supervisor must initial or sign at the BLACK to indicate 40
garments have passed consecutively.
8. This document has been designed to allow the creation of a record of operations,
operators, process confidence using Black, Red, Yellow and Green signals to clearly
show the process status and remedial actions carried out. Each line of the record will
enable 10 audit samples to be recorded. Using a line per operator will accommodate
the Normal frequency of audits of 2 per shift.

Traffic Light Implementation IPC Report

Attachment – 1. Operator Daily Quality Performance Sheet (IPC Report at Machine)

Attachment – 2 – Quality Standard and Specification for Sewing Line
Attachment – 3 – Quality Standard and Specification for Finishing
Attachment – 4. IPC Report at Sub Assembly
Attachment – 5. IPC Report at Assembly line
Attachment – 6. Top 5 Problems
INLINE INSPECTION PROCEDURE
I. PURPOSE
To ensure the manufacturing process is constantly monitored to ensure products conform
to Customer specification throughout the manufacturing process.

II. SCOPE
 Inline Inspection is a method of random inspection in-between processes. This has to be
done to enable to detect any possible defects/faulty parts or processes that have an effect
with quality, and to alert all people concerned, at the earliest stage.

III. WHEN AND WHERE

The procedure is carried out at the end of sub assembly production line.

IV. PROCEDURE
1. The trained inline inspectors work in some specific areas to give additional support for
quality. The daily inspection areas has to be established based on the recorded result
of end-line inspection of previous shift – processes with the top 3 (worst) repair rate
must be the top priority for inspection.
2. A Measuring Tape has to be always with the Inline Inspector. Process Standard,
Approved Contract Seal, PP Note, CMS, Bulk Component Card, Approval Card, & Fabric
Standard has to be provided, if required, for further verifications.
3. Inline inspectors randomly check products for any possible defects or faults in the
production process. Once a fault or defect is detected, a defect (red arrow) sticker has
to be attached to faulty part of the product, and the inspector has to record the fault
into her Inline Inspector Report Sheet.
4. All product with fault must be returned to each respective operators, and The Inline
Inspectors must inform the Production Supervisor or Trainer, for further actions and
rectifications.
5. All repaired products for faults must be returned to the Inline Inspector for re-
inspection.
6. This inspection has to be repeated until there is a significant improvement at the inline
inspection stage for these 3 particular processes, and the operator may only able to
move to other processes if any worse problem/repair rate arises at the inline
inspection stage
 Inline Inspection Activity

Attachment – 1. Inline Inspection Report

BUTTON TEST (BINGO CARD) PROCEDURE
I. PURPOSE
To determine the level of feasibility / performance of button attached machine condition,
the button condition and stitching condition in the production area.
II. SCOPE
This procedure is applied to all buttons for all garments produced for Marks and Spencer
in PT. Dewhirst Menswear. The button-test (Bingo Card) will be done for all kinds of in
Production/Sewing floor stages.

III. WHEN AND WHERE

This procedures carried out on all buttons during Sewing process (by the in-line QC) –
once per two hour in every shift.

IV. PROCEDURE
1. Each button attached machine will be tested as describe in this method
a. Each button attached machine will be tested to feasibility of mounting machine
condition, the button condition and stitching condition during run production.
b. The button attached into the Bingo Card carried out by the button attached
operator once per two hour in every shift.
c. The examination of button condition on the Bingo Card conducted by the QC in
line / IPC at least once per two hour in every shift.
d. Ensure the button inspection result is recorded into the Bingo Card and attached
on each button attached machine.
2. During the button attached phase, the buttons specimen are required for attaching
the button into te Bingo Card by the attaching button operator during the production
run. Actual button samples and the thread which used to attached into the Bingo Card
must match with the actual of button and the thread used during bulk production or
production runs.
The button test results must be reported to the QC Manager, the production and to
the Engineering if required, for each T-numbers/products.
3. During Sewing/production, all buttons for all M&S products, are required for button
pull-test once per two hour in every shift. Actual buttons must be attached onto the
bingo card with correct/exact materials used in bulk production.
4. All FAILED bingo card results must be reported to the QC Manager and Engineering, if
required, for each factories/T-numbers.
5. Do the buttons test which attached the button in each machine, observe the sample’s
(button and the stitching) condition and give the conclution.
a. The result is PASS, if the stitching condition are not broken/torn, or the button
condition is not damaged.
b. The test result is FAIL, if button Damage on button, or broken-stitches appears.
 6. Check the condition after test, if the breakdown was due to thread or button
attachment breakdown. Coordinate with the QC Manager, the Production and
Engineering for decision making about the breakdown caused accessories and thread.
7. The test result must be recorded in the Dewhirst Hourly Button Procedure / Bingo
Card (see attached -1) completely and correctly within the button by the button
attached operator. These files, must go into each respective button attached machine,
and must be always available for review at any time. The Bingo Card always be
installed on the machine even if the machine has been changed line or move to
another factory.

Attached 1 : Bingo Card

a. First Page
b. Second Page
SEWING NEEDLE CONTROL AND SHARP TOOLS PROCEDURE
I. PURPOSE
To ensure that PT.Dewhirst’s product is safe from from metal contaminant and all needles
are held in secure, known location, before issue, within process and after return from
 manufacturing process. This procedure is designed to control the machine needles and
other similar needle types within the manufacturing process and the control and
distribution of sharp tools on the production floor.

II. SCOPE
Applies to all production locations of a supplier (including sample rooms, main and
approved sub-contracting locations and accessory suppliers).

III. WHEN AND WHERE

This procedures carried out on all activity during production process

IV. PROCEDURE
1. The sewing needle control and the sharp tools desk must be located in a known and
secure place within the manufacturing floor and controlled by trained needle control 1
(one0 operator per shift under QC Manager’s Responsibility.
2. All needles stock and the sharp tools must be stored in a secure and lockable case with
drawers with only approved personnel having access to the case key. A clear and
concise record of needles being stored and issued must be maintained at all times and
available for security. This procedure applied also for the storage of the hand-sew
needles and the needle of the kimble tag gun needles.
3. The needle and sharp tools personnel must be fully trained in the requirement for the
procedure and be capable of dealing with the one to one needle replacement and
distribution of the sharp tools process, appropriate records maintenance, and the
strict application of the security measures to ensure that the needles and the sharp
tools cannot obtained unless under their control. She must always stationed in the
needle procedure desk. During the break time, she must be replaced by QC supervisor
or Assistant Manager.
4. The production operator or his/her Superior (Supervisor, Operations Manager, QC and
Factory Manager) are prohibited to carrying their own needle (both the needle for
sewing machine or hand-sew needle) come from outside PT.Dewhirst. If case of
violation, disciplinary action will be applied to the PT.Dewhirst’s Management.
5. Ensure the garment which has been transfered to the Finished Goods has been
inspected and free from needle and metal contamination that carry over from the
production.
6. At the time of taking the needle stock from the Consumable section or at the time of
return the needle to the Consumable section, the needle personnel/QC Needle must
be fill in the needle Handover form and give her signature. The needle personnel also
must updated the needle stock immediately on the needle stock control log.
7. Complete or broken needle replacement
a. The sewing operator must carry the needle and/or all broken needle parts in a
special needle box with magnet inside and closed. Any Needle carried to the
needle control person without the required needle box will not be replaced.
b. Sewing operator must bring the needle to the needle store desk and ask for the
needle replacement after giving the used needle. Any Needle carried without
needle box will not be replaced.
c. Needle Personnel must check and record the used needle prior to give the
replacement needle. For broken needle with complete parts, it must be checked
and ensure that all parts of broken needle are found and complete.
d. To prevent the garment contaminated by the needles, although the needle to be
exchanged is still intact, the sewing operator must carry the garment is being
produced on the machine (in a lock box) to the needle personnel for examination
with a hand held detector.
e. The needle administrator attached the old needle that has been exchanged into
the Dewhirst Broken, Bent and Blunt Needle Control Worksheet and Record
(please see the attachment-3) and ensure only one piece of needle (except the
double needle) attached in the one coloum and ensure only one type of needle
attached in the one sheet. In one week, the sheet must be collected and deposited
to the Complience for the needle destruction.
f. If the machine is not used for production, ensure the needle has been detached
from the machine by sewing operator or by the Engineering and has been returned
to the needle operator. Also ensure the unused machine has been inspected and
free from the broken needle or other metal contaminant by the needle operator
and The Maintenance/Engineering.
8. In the event of part of a needle not being found/missing.
a. The sewing operator must secure the garment which has being processed while
the needle broke and put it in the special box available in each line. (Do not do the
needle checking to the garment at this stage).
b. She must look for the broken needle part(s) in her surrounding working area
manually. If the part(s) cannot be found, then she must report to her supervisor
and then bring the garment (in the lock box) to the needle control desk.
c. The supervisor will ask to needle control person to borrow the hand held metal
detector to search for the part(s) in the working area or borrow the magnet pen to
search for the part(s) at the oil box at the sewing machine or the large magnet to
search the needle part on the floor around the machine on the floor about 1.5M 2.
d. The working area must be thoroughly checked for the part(s), if the part(s) not
found then they must go back to the needle control desk to check the garment.
 The needle inspection on garment must be carried out at the metal free area near
the needle control desk and do not remove the garment from the box during the
inspection.
e. If the broken needle part cannot be found, the supervisor must report to the
manager and ask for his/her signature for acknowledgement on the needle
request form.
9. The garment with the metal-free contaminat requirement, ensure the garment is done
100% by with the conveyor metal detector scaning process before it is inserted into
the box. Ensure the garment also has been re scanning over the garment has been
conducted the audit (both pre final and final inspection).
10. The metal detector (both the hand held metal detector and conveyor metal detector),
the calibration process must be done once every two hours of use and recorded onto
the calibration log book and signed by the calibration operator.
11. Borrowing and returning the sharp tools:
a. The production operator should write down the type and quantity of tools and the
time out at the Tools Issuing Control Record (Daily).
b. The needle and sharp tools administrator provide the tools which has sharp tools
(scissors, screwdrivers, twizzer, sewer’s pick and so on) to the production
operator. Time of borrowing in the tools has conducted at early shift of began to
work.
c. When the tools used on the shop floor (sewing), ensure the sharp tools has tied to
the machine (e.g scissor) or on the secure place (screwdrivers, twizzer, sewer’s
pick and other sharp tools which can not tied to the machine).
d. The Operator must have returned the tools to the needle and sharp tools
personnel if the operator will leave from the work place (as it will break or while
going home) and write down the time of return on the form Tools Issuing Control
Record (Daily).

Garment Contaminated Box, Needle Exchange Box

 Magnet Pen, Large Magnet

Calibrated Hand Held Metal Detector Saving The Contaminated Garment into the box

Searching the broken needle at the Searching the broken needle on the machine

Garment on plactic table

Attachment-1 – Dewhirst Broken, Bent and Blunt Needle Control Worksheet and Record
Attachment – 2 – Tool Issuing Control Record (Daily)

Catatan Harian Pengendalian Pengeluaran Alat – Alat Kerja

Tool Issuing Control Record (Daily)

Attachment – 3 – Tag Gun Control Sheet
Attachment 4 – Metal Detector Inspection Report
Attachment 5 – Metal Detection Calibration Log
GARMENT WASH TEST PROCEDURE
I. PURPOSE
This procedure serves as guide when conduct the garment wash test (the scope of the
care label and durability wash) while ensuring that the M&S Standard and Dewhirst
operational procedures are followed.

II. SCOPE
The garment wash test process shall be followed/referenced by any or all of the
following : (1) Gartech Technical (2) Fabric Technical (3) Laundry/Laboratory and (4)
 Quality Control and for each type of garment produced in PTD. Garment wash test consist
of Durability Wash (do at time of pilot production) and Care Label Wash (do at the time of
production runs or normal wash)

III. WHEN AND WHERE

The garment wash test process conducted once per 5000 garment per style or based on
quantity order (with monitoring quantity per PO). The Durability Wash conduct once at
the time of production pilot by the QC Tester. The garment wash conduct in the Fabtech’s
Laboratory.

IV. PROCEDURE
1. QC Manager/Assistant can monitor the production output quantity and can take the
garment from the B grade with the critical path. If there is no production output B
grade then the QC coordinate with the Merchandiser regarding the garment from
which PO. For durability wash, the QC Manager/Assistant can prepare the garment
from the production pilot.
2. The QC provide the B grade garment (with manufacturing problem) to do the garment
wash test (care label wash). The number of garment will do the garment wash test is
one out every output of production 5000 garment per style. For the durability wash,
the QC prepare one garment from the production pilot per style.
3. The QC measure the garment prior to do the garment wash test such as half chest,
sleeve, collar, front, and back (for the shirt) or waist and inseam/inside leg (for the
trouser). The data should be inputted into the Garment Wash Report. The data should
be kept and controlled by the QC.
4. The QC handed over the garment with the document to the Accredited QC Tester (Euis
for T18, Talbots Trouser and T25, Ela for T11, Talbots Blouse, LWR Blouse and Trouser
and Express) to do the garment wash test in the Laboratory FabTech.
5. QC Tester conduct the grading stitching pucker test and general appearance (DP
Rating, delamination and Critical Assessment) before do the garment wash test. The
measurement results inputted into the Garment Wash Report and archieved by QC
Tester.
6. QC Tester conduct the garment wash in the Fabtech’s laboratory. For the detail of the
garment wash process is technically described in the M & S testing method for
garment wash (Laboratory’s Procedure).
7. The garment has been done the garment wash test then do the grading stitching
pucker test and general appearance (DP Rating, delamination and Crititcal Assesment)
by QC Tester. The result of the grading pucker and general appearance input into the
 Garment Wash Report (please see the attachment below). The records kept and
archieved by the QC Tester.
8. The garment has tested the grading pucker then given to the QC to do the
measurement process garment after washing such as half chest, sleeve, collar, front
and back (for the shirt) or waist and inseam/inside leg (for the trouser). The
measurement results then inputted into the Garment Wash Report and archieved by
the QC.
9. The QC also should be checked poor seam performance, poor attached trims and
shrinkage (measurement) performance. For colour fastness test, the QC coordinate
with the Fabtech’s laboratory for making decision about the quality. The result of the
poor seam performance, poor attached trims and shrinkage (measurement) then
input into the Garment Wash Report. The records kept and archieved by the QC.
10. Garment pressing process done, then the QC do the measurement after the pressing
process, such as half chest, sleeve, collar, front and back (for the shirt) or waist and
iseam/inside leg (for trouser). The measurement results then inputted into the
Garment Wash Report and archieved by the QC.
11. The garment and the Garment Wash Report given to the accreditation Tester QC then
do the grading pucker measure (DP Rating) and general appearance test after the
pressing by the Tester QC. The result of the grading pucker after pressing input into
the Garment Wash Report by the Tester QC.
12. Do the Garment Wash Test for Durability Wash once in every production pilot and for
care label one out of every output of production 5000 garment for each style by the
Tester QC. Once the Care Label Wash is five times of washing and measured once time
at the time before washing (before and after pressing) and five times at the time of
after washing (before and after washing) by the QC and the Tester QC.
13. The garment that completed tested, then stored in the chiller room for archieved by
the Tester QC. The overall Garment Wash Result Form archieved and kept in each
style by each QC.
 Garment Wash Test Machine

DP Rating & the Standard (AATCC)

Attachment – 1 – Garment Wash Test Report

BUTTON PULL TEST PROCEDURE
I. PURPOSE
To determine the level of strength and condition of the button and the stitching or fabric
condition at the time of pull test.

II. SCOPE
This procedure is applied to all buttons for all garment produced for Marks and Spencer in
PT. Dewhirst Menswear. The pull-test will be done for all kinds of buttons at Trims
Warehouse, Sample Room, and in Production/sewing floor stages.
III. WHEN AND WHERE
This procedures carried out on all buttons, in the Trims Warehouse (by Trims QC) – after
arrival and prior to issuance to the production. During sample making stage (by the
Sample QC) – 1X test for the sample. During sewing process (by the in-line QC) – once in
every shift. All test will be conducted at the Gartech (Mezzanine office) using the “THE
Housfield” digital pull-test machine.

IV. PROCEDURE
1. Each accessories specimen will be tested as describe in this method.
a. Each sample button will be tested to destruction and the load at which the
breakdown occurred to be noted.
b. The test should be conduct by QC (Trims, Sample or Sewing In-Line QC) person
which already trained on pull testing.
c. Must be remember to always wear the safety googles when conducting the test.
2. During Sample making stage, the buttons are required for pull-testing, by the Sample
QC. Actual button samples will be attach on mock-ups which fabric/components and
stitching combinations used are the same as the actual to be use in bulk, for pull-
testing. Pull test results must be reported to the Gartech Coordinator, Trims
Purchaser, and QC Manager for each T-numbers/products. This test has to be done at
least once for each sample produced by stroke-numbers.
3. Every receipt of the very first delivery of the buttons, and prior to issue to the
production, the Trims QC will take button samples then attach on mock-ups which
fabric/components and stitching combinations used are the same as the actual to be
use in bulk, for pull-testing.
4. Pull-test results must be reported to the Gartech Coordinator, Trims Purchaser, and
Sample Room Manager, and Fabric Technologist, for each T-numbers/products. The
pull-test is has to be done only once for any new button/item, upon the very first
delivery. During Sewing/production, all buttons for all products, except
Childrenswear/Boyswear products, are required for button pull-test once in every
shift.
5. For all Childrenswear/Boyswear products, a pull-test for every 2 hours is required.
Actual buttons must be attached onto the mock-ups with correct/exact materials used
in bulk, for pull-testing.
6. Preparing materials and kits for button pull-test
a. Materials for mock-ups (fabric, buttons, thread, interlining) must the same as
mentioned on PPNote and attached on Bulk Component Card.
b. Correct/proper machinery and machine settings, for attaching the buttons, must
be used/applied for the mock-ups for testing.
 c. Prepare the Pull-Test machine, and make sure that all settings are correct.
7. Suitable load for the test in accordance with the requirement is 70 N (7.14 kgs). The
velocity during test is 200 mm per minute constant rate of traverse.
8. Do the pull test and observe the sample’s condition at the time use the load 70 N (7.14
kgs) for 10 second.
a. The result is PASS, if the stitching/fabric condition are not broken/torn, or the
button condition is not damaged at the time/before the load of 70 N (7.14 kgs) is
achieved for the duration of at least 10 second.
b. The test result is FAIL, if :
 Damage on button, rip on fabric, or broken-stitches appears before the
machine scale achieve 70 N.
 Damage on button, rip on fabric, or broken-stitches appears within less than
10 seconds, after the pul-test machine achieved 70 N.
9. Check the condition after test, if the breakdown was due to thread, fabric or button
attachment breakdown. Coordinate with the Gartech Coordinator, Production and
Merchandiser for decision making about the breakdown caused accessories and
thread, or with Fabric Technologist for decision making about the fabric problem.
The test result must be recorded in the In-Line Pull-Test Record completely and
correctly (include the date, time, tester, machine number, position, and the test
result) within the mock-up by the QC (Trims, Sample Room, or In-Line QC). These files,
must go into each respective style-file, and must be always available for review at any
time.
10. Tests result must be kept for at least 12 months for all Menswear & Ladieswear
products. Pull-test results for all Childrenwear/Boyswear products must be kept for 18
months.
Attachment – 1. In-line Pull Test Record
ENDLINE INSPECTION PROCEDURE
I. PURPOSE
To detect any defective or faulty garment, and to avoid these garments to be move into
the Finishing area.

II. SCOPE
End line Inspection is a method of 100% inspection at end of sewing processes. This has to
be done to enable to detect any possible defects/faulty parts or processes that have an
effect with quality, and to alert all people concerned, at the earliest stage.
III. WHEN AND WHERE
The procedure is carried out at the end of assembly production line.

IV. PROCEDURE
1. Final/Assembly QC Inspection is a method of 100% check on all products crossing at
this point. The purpose of this inspection is to detect any defective or faulty garment,
and to avoid these garments to be move into the Finishing area.
2. The trained Final/Assembly Inspectors work at the end of each Final or Assembly line.
An inspection table must be provided as a working station for the Final/Assembly
inspectors. Sufficient llightings, using 840 P15 T8 light, is required.
3. Production Standards, Measurement Patterns. Approved Contract Seal, PP Note, CMS,
Bulk Component Card, Approval Card & Fabric Standard has to be provided, if
required, for further or immediate verifications.
4. Garments have to be checked for make-up, stitching, fabric appearance, and trims.
The measurement on certain parts of the garment has also needed to be checked
100% at this point (critical point), i.e.; Trouser/Skirt: Leg length & Waistband,
Shirt/Blouse : Colar Length.
5. End line/Assembly inspector checks 100% all products for any possible defects or
faults at the end of End Line/Assembly lines. Once a fault or defect is detected, a
repair tag with diagram (pictures) has to be attached, onto the garment by the
examiner. An “X” – mark has to be witten on the attached tag, indicating the exact
location/position of the garment fault/s.
6. Each defect found on the garment has to be represented by an X-mark on the repair
tag. The examiner has to write “INSIDE” besides the X-mark if the problem is inside the
garment, and no need to put extra wordings for all sort of defects on outside part.
7. Except for button-attach problem, all defects/faults have also be identified by red-
arrow sticker (repair sticker) by the examiner, before the garment has to be send back
to production for repair.
8. The fault has to be recorded by the examiner accordingly into her inspection report.
9. Once the fault/s had been rectified by production, the person who did the repair must
encircle each respective X-mark accordingly. No garments are allowed to move into
the Finishing or at next stage without being inspected and released by the End
Line/Assembly inspector.
10. A garment can only be counted as one fault. In the event that there are more than one
type/kind of fault in garment, the more serious defect overweight the other, i.e.; in a
garment has two faults – ‘broken stitch’ and ‘uncut thread’, then the ‘broken stitch’
has to be recorded as this regarded as more as serious fault that the ‘uncut thread’
11. All products with fault must be returned to each respective operators by the line
mover and the End Line/Assembly Inspectors must inform the Production Supervisor
or Trainer, and the QC Supervisor with the Garment Technologist for further actions
and rectifications, if the fault or defect goes continuously.
12. The End Line/Assembly Inspector or the QC Supervisor must also to inform the Inline
QC Inspector for the top 3 fault found on each shift at each line, to enable the Inline
QC Inspector established the most priority process to check.
13. All repaired products for faults must be returned to the End Line/Assembly Inspector
for re-inspection. Repaired garment has to be reexamined by the examiner through
each respective fault/s, using the attached repair tas as reference. No examiner is
allowed to put the QC pass sticker on the garment unless all faults/defects had been
rectified/repaired correctly.

Endline Inspection Activity

Attachment – 1. Endline Inspection Report

FINAL QC INSPECTION PROCEDURE
I. PURPOSE
The purpose of this inspection is to detect any defective or faulty garment, and to avoid
these garments to be move into the Finished Goods Warehouse or into Vacpack. This also
serves as a final filtering point for the garments before the Manufacturing or Shipment
Release Audit.

II. SCOPE
Final QC Inspection is a method of 100% inspection at end of finishing/pressing processes.
This has to be done to enable to detect any possible defects/faulty parts or processes that
have an effect with quality, and to alert all people concerned, at the earliest stage.
III. WHEN AND WHERE
The procedure is carried out at the end of finishing/pressing production line.

IV. PROCEDURE
1. The trained Finishing Inspectors work at the end of each Finishing area. An inspection
area must be provided as a working station for the Finishing Inspectors. Sufficient
lightings, using D65 light, is required.
2. Production Standards, Measurment Patterns, Approved Contract Seal, PP Note, CMS,
Bulk Component Card, Approval Card, & Fabric Standard has to be provided, if
required, for further or immediate verifications.
3. Garments have to be checked for presentation, pressing, garments appearance, trims
and packaging accessories, if available. If applicable, the measurement on some parts
of the garment has also need to be checked at this point (critical point), ie: Washing
Garments.
4. Finishing inspector checks 100% all products for any possible defects or faults at the
end of Finishing area. Once a fault or defect is detected, a defect (red arrow) sticker
has to be attached to faulty part of the garment, and the inspector has to record the
fault into her Finishing Inspector Report sheet. No garments are allowed to move from
the Finishing Area without being inspected and released by the Finishing inspector.
5. A garment can only be counted as one fault. In the event that there are more than one
type/kind of fault in a garment, the more serious defect overweight the other, ie; in a
garment has two faults – ‘broken stitch’ and ‘uncut thread’, then the ‘broken stitch’
has to be recorded as this regarded as more serious fault that the ‘uncut thread’
6. All products with fault must to be returned to each respective line by the Finishing
mover, and the Finishing Inspectors must inform the Finishing Supervisor or Trainer,
and the QC Supervisor with the Garment Technologist for further actions and
rectifications, if the fault or defects goes continuously.
7. The Finishing Inspector or the QC Supervisor must also inform the Endline QC Inpector
for the main fault found on each shift. This to enable the Endline QC inspector to be
more aware of the problem that they may missed at the endline inspection.
8. All repaired products for faults must be returned to the End line/Assembly Inspector
for reinspector.
 Final QC Inspection Activity

Attachment – 1. QC Final Inspection Report

 Section - 3 :
After Production Activities
SHIPMENT RELEASE AUDIT PROCEDURE
I. PURPOSE
To assess stock as it is delivered to the finished goods & vacpac warehouse. Comparing
stock against the approved contract seal and style file information. The carrying out off
this activity will ensure that the greatest level of confidence can be assured prior to
garments being shipped. The audit criteria will trigger positive garment acceptance into
the finished goods/vacpac warehouse when the minimum requirements are achieved or
reject / return stocks when not achieved.

II. SCOPE
The Shipment Release audits must be conducted on finished garments with ALL
packaging, trims and labels attached, basic seam construction and safety requirements.
III. WHEN AND WHERE
The Shipment Release audits will be conducted within the finishing area. Audits will be
performed daily on all garment produced at PT.Dewhirst Menswear.

IV. PROCEDURE
1. To assess stock before it is delivered to the finished goods. Comparing stock against
the approved PPS and style file information.
2. The Shipment Release audits must be conducted on finished garments with ALL
packagaing, trims, and label attached. The audit will cover : - All aspects of garment
construction, presentation, measurement (5 critical measurements based on the
Garment Zoning Guideline).
3. The Shipment Release audits will be conducted within the shipment realease area.
Audits will be performed in each production respectively.
4. Shipment Release audits will be conducted on every transfer / delvery from the
finishing and the audit must be conducted before making the transfer note. The
transfer note can be made after the audit is pass. Every hour, there should be at least
one audit done per style (a maximum of 4 – 5 running style and 3 – 4 audit will be
done each hour).
5. The auditor must measure a minimum 16 garment per shift, covering all sizes. This will
depend on avaibility of goods. The batch size of each audit will be determined by each
quantity transferred from the finishing.
6. Garments will be audited using AQL Normal Level II, 1.5% , BS6001 : 1999.
7. Each batches for transfer will be held in a quarantined area until the audit has been
fully completed. NO garments to be moved until the audit is fully completed and the
results are known.
8. If the audit passes, then the stock can be moved from within the quarantined area.
Rejected / failed samples MUST be returned to the factory for repair, and the
garments within the batch of the failed style will be 100% checked for the specific
fault. The numbers of faults found must be recorded on the 100% inspection
document, and has to be filed by the QC and a weekly summary has to be given to FM,
QC Manager, and Site QC Manager for further analysis/action.
9. Further reaudit must be conducted on all garments/batches after 100% re inspection
had been completed. Result for the second audit must be recorded using the normal
audit form/sheet and has to be inputted into the system.
10. On any audits that fails, then the auditor, QC Manager or Assistant QC Manager and
the Operations Manager MUST sign to accept the audit results. Action plans, if
required, MUST be completed by the QC and Operation Manager.
11. Record the result of audit into the AQL Audit Form.
 12. Put the garment (in a bundle) into the box and put the “AUDIT PASS” sign and ready to
transfer to the Finished Goods.
13. Garments found with faults MUST be repaired if the audit result is also a ‘Pass’. The
faults must be identified using the ‘red arrow’ stickers. Garments are to be returned
immediately to Production for repair. A summary of faults found on garments written
on a paper tag which will be clearly attached on the belt loop. All faulty garments has
to be kept and to be discussed with the FM, OM, QC Manager & Asst QC Manager, by
the auditor and Asst Audit Manager, on the work day latest.

Contract Seal

Shipment Release Audit Activity Style File Rack

 Quarantine Area For Audit Passed Area

Failed (100% QC Double Check) Area

Attachment – 1 Single Sampling Plan Normal Level II Inspection

Attachment-2 – AQL Audit Form
WAREHOUSE ACCEPTANCE AUDIT PROCEDURE
I. PURPOSE
To assess stock as it is had delivered to the finished goods warehouse. Comparing stock
against the approved contract seal and style file information. The carrying out off this
activity will ensure that the greatest level of confidence can be assured prior to garments
being shipped. The audit criteria will trigger positive garment acceptance into the finished
goods / vac pac warehouse when the minimum requirements are achieved or reject /
return stocks when not achieved.

II. SCOPE
The Warehouse Acceptance audits must be conducted on finished garments with ALL
packaging, trims and labels attached, basic seam construction and safety requirements.

III. WHEN AND WHERE

 The Warehouse Acceptance audits will be conducted within the finished goods area on
every transfer / delivery from the factory. Audits will be performed daily on all garment
produced at PT.Dewhirst Menswear.

IV. PROCEDURE
1. To assess stock after it is delivered to the finished goods. Comparing stock against the
approved PPS and style file information.
2. The Warehouse Acceptance audits must be conducted on finished garments with ALL
packaging, trims and labels attached. The audit will cover : - All aspects of garment
construction, presentation, measurements (5 critical measurements based on the
Garment Zoning Guideline).
3. The Warehoouse Acceptance audits will be conducted within the Finished Goods
area/Warehouse Acceptance area. Audit will be performed in each production
respectively.
4. Warehouse Acceptance audits will be conducted on every transfer / delivery from the
factory and the audit must be conducted after receive the transfer note.
5. The auditor must measure a minimum 16 garment per shift, covering all sizes. This will
depend on avaibility of goods. The batch size of each audit will be determined by each
quantity transferred from the finishing.
6. Garments will be audited using AQL Normal Level II, 1.5% , BS6001 : 1999.
7. Each batches for transfer will be held in a quarantined area until the audit has been
fully completed. NO garments to be moved until the audit is fully completed and the
results are known.
8. If the audit passes, then the stock can be moved from within the quarantined area.
Rejected / failed samples MUST be returned to the factory for repair, and the
garments within the batch of the failed style will be 100% checked for the specific
fault. The numbers of faults found must be recorded on the 100% inspection
document, and has to be filed by the QC and a weekly summary has to be given to FM,
QC Manager, and Site QC Manager for further analysis/action.
9. Further reaudit must be conducted on all garments/batches after 100% re inspection
had been completed. Result for the second audit must be recorded using the normal
audit form/sheet and has to be inputted into the system.
10. On any audits that fails, then the auditor, QC Manager or Assistant QC Manager and
the Operations Manager MUST sign to accept the audit results. Action plans, if
required, MUST be completed by the QC and Operation Manager.
11. Record the result of audit into the AQL Audit Form.
12. Put the garment (in a bundle) into the box and put the “AUDIT PASS” sign and ready to
transfer to the Finished Goods.
 13. Garments found with faults MUST be repaired if the audit result is also a ‘Pass’. The
faults must be identified using the ‘red arrow’ stickers. Garments are to be returned
immediately to Production for repair. A summary of faults found on garments written
on a paper tag which will be clearly attached on the belt loop. All faulty garments has
to be kept and to be discussed with the FM, OM, QC Manager & Asst QC Manager, by
the auditor and Asst Audit Manager, on the work day latest.

MANAGEMENT AUDIT PROCEDURE

I. PURPOSE
To enable all managers to be involved in assessing stock, comparing against the approved
Factory standard and/or Approved Contract Seal and viewing these garments as if they
were a normal customer.

II. SCOPE
This audit will cover mainly on garment presentation, workmanship, and component
(Accessories), but if there is any other fault found this should be reported.

III. WHEN AND WHERE

The Management Audits will be conducted at finished goods/warehouse area. This audit
activity must be carried out on garments which have been inspected and released by the
 Shipment Release Auditors, and /or finished goods/vacpack warehouse, with all packaging
trims and labels attached.

IV. PROCEDURE
1. The carrying out of this activity will ensure that the greatest possible level of
confidence can be assured in finished garment stock consistency and standards
achievement. Managers must ensure that this activity is used to give direction to other
auditors and to all areas/department involved that have to do with the quality, and to
achieve on going golobal higher standards of excellence.
2. The audit assessment criteria will trigger positive product acceptance into Dewhirst
finished goods warehouse as the minimum requirements are achieved, freeze or
reject/return stock when not achieved. This audit activity will also install discipline into
garment assessment, increasing general awareness of standards required, creating a
sense of ownership and responsibility in those involved.
3. The QC Asst Managers and Garment Technologist can do the Management Audit on
the First Bulk Production even before the garments has to be inspected by the
Shipment Release Auditors, and packaging trims/labels are not necessarily
attached/complete.
4. Styles and/or colours to be audited one to be recommended by the Auditor or Asst
Audit Manager. New styles/design, garments and/or fabric construction, and even
current styles with many problems have to be prioritized for audits.
5. The Management Audit must be carried out as specified on the schedule in a period.
The sample size to be audited are 8 pcs. For Senior Management, the audit must be at
least 6 times per period (3 for menswear and 3 for Ladieswear) the audit must be
done some at finished goods/warehouse. A minum number of audit per period for
other managers/staff is required as specified on the schedule which will be sent by
email by the Audit Asst Manager/administrator at each period-ends.
6. Garments will be audited using AQL Normal Level II , 1.5% , BS6001 : 1999. If there is
any fault found, audit will be fail.
7. The management auditor must fill in the audit form and sign it off once the audit
done. If the audit pass, the form has to be given to the directly to the auditor, and if
fails, the form must be given to QC Managers/Asst and/or Audit Asst Manager to
discuss with Factory Manager and/or Operations Manager and with the QC & audit
team respectively.
8. Audit results will be entered on to the E – quality system as Shipment Release Audit.
SHIPPING COMPLIANCE AUDIT PROCEDURE
I. PURPOSE
To assess stock as it is had delivered to the finished goods warehouse. Comparing stock
against the approved contract seal, PO and style file information. The carrying out off this
activity will ensure that the compliance to the packing accurancy can be assured prior to
garments being shipped. The audit criteria will trigger positive garment acceptance into
the finished goods warehouse when the minimum requirement are achieved or
reject/return stocks when not achieved.

II. SCOPE
The Shipping Compliance audits must be conducted on boxed/hanging garments with all
packaging, trims and labels attached, construction, the accuracy for the quantity and
safety requirements.
III. WHEN AND WHERE
The Compliance Shipping audits will be conducted within the finished goods area on every
transfer / delivery from the factory. Audits will be performed daily on all garment
produced at PT.Dewhirst Menswear prior to loading the container.

IV. PROCEDURE
1. Compliance audits will be conducted after packaging, full quantity and after receiving
the packing list.
2. To assess stock after it is delivered to the finished goods. Comparing stock against to
approved PPS, PO and style information.
3. Garments will be audited using Compliance Inspection Table Standard.
4. Each batches for transfer will be held in a quarantined area until the audit has been
fully completed. NO garments to be moved until the audit is fully completed and the
results are known.
5. The stock will check for the PO number (against the PO sheet), box dimension (against
the Tech Pack/information from Merchandiser and packing list), label and other
accessoried (against the BCC), and its quantity accuracy (against the packing).
6. If the audit passes, then the stock can be moved from within the quarantined area.
Rejected / failed samples MUST be returned to the factory for repair, and the
garments within the batch of the failed style will be 100% checked for the specific
fault. The numbers of faults found must be recorded on the 100% inspection
document, and has to be filed by the QC and a weekly summary has to be given to FM,
QC Manager, and Site QC Manager for further analysis/action.
7. Further reaudit must be conducted on all garments/batches after 100% re inspection
had been completed.
8. Put the garment into the box and put the “AUDIT PASS” sign and ready to release for
dispatching at the Finished Goods.
Attachment – 1. Compliance Inspection Table Standard
Attachment – 2. Shipping Compliance Audit Report
HANDLING GARMENT PROCEDURE ON THE FINISHED GOODS
WAREHOUSE AREA
I. PURPOSE
To ensure all the goods stock is transferred to Finished Goods Warehouse, scan packed
and loading shipment with the correct standard.

II. SCOPE
All the procedure conducted at the Finished Goods Warehouse and conducted by the
finished goods person.

III. WHEN AND WHERE

The procedure conducted at the finished goods area on every transfer / delivery from the
factory until loading to the container.

IV. PROCEDURE
1. Transferring garment from factories
a. The transfer of goods – all garments should be sent to central dispatch by
truckers / mover, this truck should be locked and opened by security, to ensure
the security aspects of these transfer process.
b. Receiving at Finished Goods – Documentation for transfer from the factories is to
be checked and to be accurate before acceptance. (This is done by the goods being
put in one specific area at the entrance to the warehouse, and the warehouse
adming scanning off the goods one by one & checking the total of garments
against the list and the signing it, meanwhile security must check the total quantity
only i.e. quantity of cartoon boxes – one copy goes back to the factory, and one
copy is kept by the warehouse and entered in JDE record for the daily report). Any
discrepancy between actual number of garments received and the paperwork
amount means that the whole transfer is returned to the factory. (this must be
followed and changing things on gate pass is not allowed) .
c. The garments send and store at specific area for the garment only that separate
with other area by well maintained physical barriers and posted with warning signs
of authorized entry only and every box come in should be record at daily journal
and match with JDE Print out at the end of shift.

2. Scanning, Packing, and Storage

a. Only a trained safety officer may restart the machine or use the reset key.
b. Ensure the entry gate to the metal-free area (before check gate area) is locked and
the key kept by the Supervisor. Only the otorized people (completed with the
special’s ID card) to entry the metal-free area.
c. Supervisor instructs operators for picking and issue goods from foods storage area.
d. Garment sent to Metal Free Detector Zone for scanning process by Central
Despatch authorized Person for Folding, Polybag and scanning process – Record
garments into Daily Checking Garment on Metal Detection Machine Record.
e. Ensure the personnel who will enter to the free metal area must keep the goods
which containing metal such as hand phone, pens, jewelry (bracelets, rings,
earings, and so on) in the appropriate place before entering to the free metal area
and recorded into the log book.
f. Before the scanning process, the Supervisor must perform 9 Point check to
machine metal detector regularly (Early Shift and Late shift of the relevant
Supervisor / 4 times in 16 hours a day) using the standard calibrator (use the
calibration card with the iron ball 1.0 mm, 1.2 mm or depend on any customer
requirements) and recorded into a 9-point check log book, if something seem
wrong with the machine, please call maintenance team ASAP.
 g. Supervisor also must perform 9 point check to machine metal detector at the time
as follow :
1) at the beginning after any stoppage both electricity jam or the beginning of
each shift
2) at the time after any maintenance
3) at te time after any clean
h. Garments are put one by one through the metal detector (for order that require a
metal detector checking).
i. Garments are in the process of scanning have problems, the the garment should fit
in a plastic bag polly then inserted into a plastic box that is locked (Contaminated
Goods Box), then the garment must be moved out of the area and in check by
using a hand held metal detector. Machines must be checked by the maintenance
team to find the problem, if the metal element not found in the garment, then
garment will be inserted to the “Destroy Goods Box” (Garment Box) and
categorized as a KILL garment. The garment which had conducted KILL, the process
must be controlled and recorded to the document/form.
j. If the scanning process Garment passed from scanning process then the garment
should be packed by using a special box and seal with ‘exclusive seal then transfer
to a special storage area then do the weight cartoon process (Note : Maximum
22.7 kilos) – Write down all the process packing into daily packing and weight
record.
k. If found irregularities to the wight of more than / less than the tolerance limit,
then the box should be opened in the presence of a security team, write the report
and take a photo process or the of the shift and the SPV is obligated to ensure this
is done.
l. Then once the cartons have been sealed, they should remain in the isolated room
until shipment or final audit.
m. The garmnet has been demolition done either at completion of the buyer’s final
audit and/or at completion of the Compliance Shipment Audit, the scanning
process must be repeated on the conveyor metal detector machine. The sequence
of garments scanning, pelase see at the point f.

3. Loading process
a. Before loading Process perfomed, restricated security line must be installed
around the container loading area and make sure no one else who is not involved
in the loading process.
b. Supervisor have to ensure that all document and all equipment/things needed for
loading activity were prepared (eg straps).
 c. Supervisor to check the container condition before loading process starts and
record findings on te report.

d. If found proble with this continer checking, take photos and report to Implex team
whether it should be replaced with the other container.
e. If there is no problem with the container, loading can start.
f. Open holding container by Spv and observed by security.
g. Spv and security start to check the quality and boxes (no broken boxes or broken
tape/strapping) and start count manually and record it on manual loading list.
h. Move all the pass counted boxes into the container.
i. Stack all the boxes as the same way stacked on holding container.
j. Make cross strings at the end of container door to prevent the goods or boxes
from falling down when unloading process at destination warehouse.
k. Close the despatch loading door after loading process completed.
l. Keep the loading areas clean and free of garbage.
m. Spv and coordinate with JDE admin to ensure all packing list are completed and
received by IMPEX Department by 13.00 for Monday-Fridays.
n. Closing Container - / See closing container procedure.

The checker segregation the goods per PO Sorting by size and put into the rack
 Scan the price ticket Scanning the garment into
the conveyor metal
detector

All scanned garment quarantined in the metal free room Garments ready to load